Adjusting the Kamaz rear axle gearbox

KAMAZ gearbox repair

Our company carries out repairs of KAMAZ gearboxes of any complexity.

Do you want to see prices for refurbished KAMAZ gearboxes?

In this article we will look in detail at how the KamAZ gearbox is repaired, common breakdowns and options for eliminating them. Kama Automobile Plant is a leader on the Russian market in the production of special equipment, trucks, and power units. Over the entire history of operation, the plant has produced more than a million cars. It is thanks to the extremely high resistance to overloads and high maintainability that these cars have earned people's love.

Repairing aggregate components on your own does not always give a positive result. Because of this, we strongly recommend that you do not perform any actions if you do not have special equipment, the necessary skills and experience, as this can lead to extremely negative consequences in the future.

Price for repair of KAMAZ gearbox

The price for this service depends on the condition of the unit and your wishes. You can find out more about the prices for repairing KAMAZ gearboxes on our website. There are a number of components that rarely malfunction. It often happens that the breakdown of a component or unit confuses the car owner.

Repair of the KAMAZ 5320, 65115 gearbox is performed extremely rarely, this is due to the good weight distribution between all aggregate units. If we talk about modern models, then repairing the KAMAZ 6520 gearbox cannot be called a popular service in service centers.

It is quite simple to identify problems in the operation of these devices: - you should be alerted by an extraneous hum. If, while moving at low speed (20-30 km/h), you hear extraneous noise, and when you increase the speed to 80 km/h, it disappears, then you will undoubtedly need to rebuild the KamAZ gearbox. Most likely, you damaged the teeth during operation; the second method of identifying malfunctions is also related to noise.

To do this, you need to accelerate your car to a speed of at least 80 km/h. After which you will have to remain at this speed, turn on neutral and turn off the engine. After which, if the teeth are damaged, you will hear a characteristic noise. The easiest way to solve this problem is to repair the KAMAZ gearbox or exchange it (replace with a new, restored, used one). There are only three main symptoms of damage to the unit: - overheating of the main gear.

The disease manifests itself in cases where there is excess oil in the crankcase of the device; - excessive noise. Wear of teeth, bearings; - oil leakage. Breakage occurs when the cuff wears out, as well as after the breather becomes dirty.

Most car malfunctions are directly related to improper operation, as well as excessive overloads. Most often, reassembly of the KAMAZ gearbox by professional auto mechanics solves most breakdowns.

You can find out how much it costs to rebuild a KAMAZ gearbox or replace it directly on the website or by calling the phone number provided.

Repair of the KAMAZ middle axle gearbox

It is extremely difficult to check the average KAMAZ gearbox and make repairs without equipment and qualified auto mechanics. Failure of the center differential or “piggy” is considered the most common case when it is necessary to repair the KAMAZ middle gearbox, as well as the “piggy” itself. When the center differential is not locked, it transmits torque evenly between the wheels.

Determining the presence of damage is quite simple: - knocking when starting the engine;

— a hum when coasting, as well as when increasing speed.

Differential locks are designed to distribute traction between the wheels that have the greatest grip on the road surface. In cases of incorrect use of the lock, the differential fails, and it is necessary to repair the KAMAZ gearbox pig.

Repair of the KAMAZ middle axle gearbox occurs in several stages: - diagnostics, visual search for possible faults; - dismantling of mechanical components; - revision of mechanical elements; - repair or replacement of damaged elements; - assembly; refilling with working fluids; - adjustment of the KAMAZ middle gearbox; - installation.

If you have special equipment and highly qualified specialists, it is possible to repair a medium KAMAZ gearbox within a few hours. Diagnostics and adjustment of mechanical components take the most time.

Repair of KAMAZ rear gearbox

In this type of work, everything happens similarly. Since in trucks it is the rear axle that is more susceptible to wear and more often requires attention. When repairing the KAMAZ rear gearbox, the following malfunctions most often occur: - deformation of the satellites; - deformation of the axle shaft; - damage to the gears;

— deformation of the carrier.

The price for high-quality repairs of the KAMAZ rear gearbox depends on the general technical condition. Repairing the rear gearbox of a KAMAZ, as well as making adjustments, is possible only with the use of special equipment. Undoubtedly, it is the adjustment of the KAMAZ rear gearbox that ensures long-term operation without breakdowns.

Adjusting the KAMAZ gearbox

This is one of the most painstaking stages of work. Adjusting the KAMAZ gearbox is a labor-intensive and complex process. The further service life of mechanical devices depends on the quality of the work performed. Adjustment of the KAMAZ axle gearbox is carried out using: - gaskets; - bushings; - nuts.

In addition, in order to adjust the KAMAZ gearbox, wrenches with a dynamometer, calipers, and other tools and devices are used. It is worth noting that the adjustment of the KAMAZ 5320 or 6520 gearbox, as well as other models, regardless of modifications and years of manufacture, is practically the same.

To summarize, it is worth noting that timely, high-quality repairs of KAMAZ axle gearboxes can ensure long-term and uninterrupted service of all vehicle components.

Source: https://dvigatelkama.ru/remont-reduktora-kamaz/

Repair and maintenance of KAMAZ gearbox

Content:

Oil level measurement

Unscrew the plug on the crankcase inspection hole; if the oil does not flow, it means that it needs to be added until it begins to drip.

Changing the oil in the KAMAZ gearbox

Changing the oil in the crankcase

bridge is carried out as follows: – unscrew the plugs of the control, drain and filler holes; – drain the used oil; – screw the drain plug into place; – fill in 5-6 liters of oil (I-12, IS-21) or diesel fuel; – start the engine, engage third gear and let the engine run at less than 1000 rpm for about 3-4 minutes; – turn off the engine, unscrew the plug and drain the flushing fluid; – re-tighten the drain plug; – fill in fresh oil and tighten all plugs. Don’t forget to clean the axle breathers: they are washed with diesel fuel and blown with compressed air.

Adjusting the KAMAZ axle gearbox

The preload of the bearings on the wheelsets is adjusted in the following order: Center differential of the KamAZ-5320 vehicle 1 - cardan flange; 2- bearing cover; 3- center differential housing; 4-spacer ring; 5- differential housing; 6- satellite; 7- satellite support washer; 8- switch; 9- fork fastening screw; 10- slider; 11 - slider; 12- return spring; 13- pressure spring; 14- glass slider; 15 - aperture; 16- hose; 17 - glass lid; 18- housing cover; 19- housing of the locking mechanism; 20- fork; 21-tooth clutch for the drive gear of the middle locking mechanism; 22- center differential locking clutch; 23- drain plug; 24- middle axle drive gear; 25- support washer; 26- cross; 27- rear axle drive gear; 28- support washer; 29-ball bearing.

sharpening or replacing adjusting washers to reduce the thickness of the package by an amount of axial displacement from 0.04 to 0.06 mm;
tightening the fastening nut of the bevel gear flange (force from 240 to 360 N);
measurement of the rotation force of the bearing cup under conditions of continuous rotation (5 revolutions) in one direction.

The turning force should be in the range from 11.4 N to 22.8 N. If the obtained value is not within the indicated limits, then the adjustment should be repeated.

When the tension of the drive and driven gear bearings is adjusted, they are installed in the crankcase. Then you need to adjust the side clearance using adjusting washers (acceptable value from 0.20–0.35 mm).

Before setting up the differential, you need to install it so that the teeth of the driven gear are symmetrical to the teeth of the drive spur gear. Then you should tighten the bolts with a force of 100–120 N. Setting up the differential includes the following steps:

uniformly tighten the adjusting nuts on both sides until a gap is obtained between the bearing tires;
measuring the gap (the value should be 0.1–0.2 mm);
tightening the fastening bolts of the covers with a force of 250–320 N.

The process of disassembling the rear or intermediate axle gearbox of KamAZ vehicles

Drain the oil;
Remove the drive axle assembly;
Disassemble it into its components sequentially: drive and driven gears, crankcase, differential box, satellite axes;
Check the condition of: crosses, journals, semi-axial gears, drive;
Replace worn products;
Adjust;

Gearbox diagram KamAZ 5320 4310 6520 65115

65115-2402011-60 - the last digit “60” means that gears with 46 and 16 teeth are installed - 498

5320-2402010-10 - the last digit “10” means that gears with 49 and 13 teeth are installed - 653

5320-2402010-20 - the last digit “20” means that gears with 50 and 12 teeth are installed - 722

5320-2402010-30 - the last digit “30” means that gears with 48 and 14 teeth are installed - 594

5320-2402010-40 - the last digit “40” means that gears with 47 and 15 teeth are installed - 543

Weight of KamAZ gearboxes 5320 4310 6520 65115 KamAZ diagram

Taking into account the transport container, the weight of the gearbox is:

— on the front axle – 132 kg; - medium - 186 kg;

— rear – 145 kg.

Choosing a KamAZ gearbox: what you need to know (Diagram of KamAZ gearboxes 5320 4310 6520 65115)

Interwheel locking

The device is mounted on the cross-axle differential. When it is turned on, the torque is divided into equal parts - between the two wheels. When the MBC is turned on, the KamAZ's cross-country ability increases. This is important when driving in difficult road conditions, for example, in icy conditions. The inter-wheel lock must be turned off in time - this will prevent gearbox damage

KamAZ 5320 - 54115, repair of drive axles instructions online

Payment for goods and downloading of the book in electronic form (PDF format) is made on the website.

To do this, you need to find the book you are interested in and click on the “Buy” button. The price of the book is indicated on the button.

For convenience, the price on the website for residents of Russia, Belarus and Kazakhstan is presented in rubles.

For residents of Ukraine in hryvnias, and for all other countries - dollars.

https://www.youtube.com/watch?v=lHv8n_xjYS8

After clicking on the “BUY” button, a payment window will open where you can select a payment system with which you can pay for the selected book using any bank card (Visa, MasterCard, MIR, etc.)

When you click on the “Pay by bank card” button, the Portmone payment system will open, which is the easiest way to make a payment.

In addition, the website offers four payment systems for payment:

Yandex (payment from any bank cards, Yandex Money account, QIWI Wallet, terminals, etc.);
Portmone (payment from any bank cards, Portmone account);
PayPal (payment from any bank cards, PayPal account);
WebMoney (payment from any bank cards, payment from WebMoney wallets).

Payment via Yandex Cashier

After selecting payment via Yandex, the Yandex Cashier payment system will launch, where you need to select a convenient payment method (bank card, QIWI, Yandex Money account, etc.)

After specifying payment details and confirming payment, payment for the goods will occur.

If you have a bank card in a currency other than the ruble, then the money will be debited from the card at the rate of the Central Bank of Russia at the time of the purchase.

This payment method is optimal for residents of Russia, Kazakhstan and Belarus.

Official website of the Yandex Kassa payment system https://kassa.yandex.ru

Payment via Portmone

After selecting payment through Portmone, the payment system will launch, where you need to select the payment method: bank card or Portmone account.

The price in the Portmone payment system is converted into dollars at the exchange rate of the Central Bank of the country where you are located.

If you have a bank card in a currency other than the dollar, then the money will be debited from the card at the rate of the Central Bank of your country at the time of the purchase.

After specifying payment details and confirming payment, payment for the goods will occur.

Official website of the Portmone payment system https://www.portmone.com

Payment via PayPal

After selecting payment via PayPal, the PayPal payment system will launch, where you need to select the payment method: bank card or PayPal account.

If you already have a PayPal account, then you need to log into it and make a payment.

If you do not have a PayPal account and you want to pay using a bank card via PayPal, you need to click on the “Create an Account” button - shown with an arrow in the picture.

PayPal will then prompt you to select your country and provide your credit card information.

After specifying the information required to make the payment, you must click on the “Pay Now” button.

Official website of the PayPal payment system https://www.paypal.com

Payment via WebMoney

After selecting payment via WebMoney, the payment system will launch, where you need to select the payment method: bank card or WebMoney wallet.

If you already have a WebMoney wallet, then you need to log into it and make a payment.

If you do not have a WebMoney wallet and you want to pay in another way, you need to select any of the methods that WebMoney offers and make the payment

After specifying payment details and confirming payment, payment for the goods will occur.

Official website of the WebMoney payment system https://www.webmoney.ru/

Downloading a book

After successfully completing the payment (by any method) and returning to the KrutilVertel store from the payment system website, you will be taken to the successful payment page:

On this page you need to indicate your e-mail, where access to download the book will be sent.

If you are already registered on our website, then simply follow the link to your personal account.

The book you purchased will be in your personal account, from where you can always download it.

Please note that after making the payment, you need to return back from the payment system website to the KrutilVertel website.

If for some reason you did not return back to the site and closed the payment system tab with a message about the successful completion of the payment, please let us know - we will send you a letter indicating access to download the book.

Problems when paying with bank cards

Sometimes difficulties may arise when paying with Visa/MasterCard bank cards. The most common of them:

There is a restriction on the card for paying for online purchases
A plastic card is not intended for making payments online.
The plastic card is not activated for making payments online.
There are not enough funds on the plastic card.

In order to solve these problems, you need to call or write to the technical support of the bank where you are served. Bank specialists will help you resolve them and make payments.

That's basically it. The entire process of paying for a book in PDF format on car repair on our website takes 1-2 minutes.

https://www.youtube.com/watch?v=IH1tdc69M7I

If you still have any questions, you can ask them using the feedback form, or write us an email at [email protected]

Source: https://krutilvertel.com/kamaz-5320-glava8-remont-vedushih-mostov

Repair and adjustment of the KAMAZ vehicle gearbox

For repairs, the gearbox of any drive axle is disassembled into several assembly units. In this case, the oil from the center differential and the axles themselves are first drained. The gearbox should be disassembled into the following elements:

drive bevel gear;
cross-axle differential (it is important to consider that its bearing caps are not interchangeable, since they are processed together with the gear housing);
driven bevel gear;
center differential (if the intermediate axle gearbox is disassembled).

If the front axle gearbox is being repaired, it is imperative to check the play of the assembly units, since the assembly must be carried out with the obligatory preload of the conical bearings. Upon completion of disassembly, all gearbox parts must be washed and checked.

Repair of KAMAZ rear axle gearbox

To disassemble the rear axle gearbox, it is necessary to unscrew the self-locking bolts used to secure the stoppers in the bearing nuts related to the rear axle differential, and also remove the stoppers.

Then you need to bend the locking plates related to the mounting bolts in the differential bearing caps. These bolts should be removed. Then you need to remove the bearing caps and differential bearing adjustment nuts. After this, remove the differential belonging to the rear axle.

Then you need to unscrew and unscrew the nut securing the flange on the rear axle and remove the flange. After this, the bolts securing the bevel drive gear bearing housing cover are turned out, the cover is removed, as well as the support washer.

Remove the bolts securing the cover and remove the cover. The drive shaft and bevel drive gear are pressed. The bolts holding the covers are removed and the covers are removed. Then you need to loosen the nut, unscrew it, and remove the support washer.

Remove the bearing cup, bearings and outer bearing race. Remove the adjusting washers and take out the bevel gear.

Adjusting the KAMAZ middle gearbox

When installing and adjusting the gearbox gears and bearings, the tapered roller bearings of the shaft belonging to the bevel drive gear must be installed after preloading.

The torque required to rotate the bearing drive gear shaft should be from 0.78 to 1.57 Nm (0.08 to 0.16 kg/cm).

_______________________________________________________________________________

Bridges of Kamaz-6520, Kamaz-65115 vehicles

Kamaz-6520 dump truck axles

Drive axles KamAZ-6520—rear and middle (for KamAZ 6460, 6520 vehicles) with a central main bevel and planetary wheel gears, with interwheel and center differential locking (for KamAZ 6460, 6520 vehicles). The difference in the design of the KamAZ-6520 axles is that the gearbox (main gear) of the middle (intermediate) axle is equipped with a center differential and individual original parts mating with it. The Kamaz-6520 cross-axle differential lock is controlled electro-pneumatically by a key switch located on the instrument panel. On Kamaz-6520 vehicles it is also possible to install “RABA” axles, which have a similar design. The gear ratio of the KamAZ-6520 bridge for models 5360, 6460 is 6.33; for the KamAZ-5360, 6460 model – 5.11. For KamAZ-6520 axles manufactured by RABA, the gear ratio is 5.648 for all models.

Rear axle KamAZ-6520 1 - wheel drive drive gear; 2 — carrier cover; 3 — thrust ring; 4 - lock nut; 5 — bearing nut; 6 — roller bearing; 7 — rear wheel hub; 8 — brake drum; 9 — rear left brake; 10 — rear axle housing; 11 — left axle shaft; 12 — main gear; 13 — right axle shaft; 14 — fork of the locking mechanism; 15 — rod of the locking mechanism; 16 — piston of the locking mechanism; 17 — rod of the locking mechanism; 18 — driven gear hub; 19 - carrier with casing and satellites.

Middle axle KamAZ-6520 1 - wheel drive drive gear; 2 — carrier cover; 3 — thrust ring; 4 - lock nut; 5 — bearing nut; 6 — roller bearing; 7 — rear wheel hub; 8 — brake drum; 9 — rear left brake; 10 — locking clutch; 11 — right axle shaft; 12 — rear shaft; 13 — drive flange; 14 — left axle shaft; 15 — middle axle housing; 16 — driven gear hub; 17 — carrier with casing and satellites; 18 – center differential; Drive axles KamAZ-6520 - rear and middle (for Kamaz-6460, 6520 vehicles) with a central main bevel and planetary wheel gears, with interwheel and center differential locking (for KamAZ-6460, 6520 vehicles). The difference in the design of the axles is that the main gear of the middle (intermediate) axle is equipped with a center differential and individual original parts mating with it. Check the oil level in the Kamaz-6520 wheel drive housings with the wheels hanging so that they can rotate freely. At the same time, install stands under the rear bogie (rear axle for 5360) and wheel chocks under the front wheels. When the manufacturer's trademark inscription is horizontal, the oil level should reach the lower edge of the inspection hole. Add oil through the filler hole by removing the plug. Do not allow oil to come into contact with the tires. To check the oil level in the KamAZ-6520 axle housing, unscrew the inspection hole plug on the axle housing. If there is no oil leakage from the inspection hole, add oil to its level through the filler hole. Drain the used oil when it is still warm from the heat of operation. To do this, lift the rear cart with a jack and place it on stands, first installing wheel chocks under the front wheels. Turn the wheels so that the inspection holes are at the bottom. Remove the plugs from these holes and the lower drain plug of the final drive housing. Protect tires from contact with drained oil. To do this, you can, for example, insert a tray made of sheet steel into the drain hole. Clean the magnet of the final drive housing drain plug from dirt. After draining the oil, replace the plugs and tighten them securely. First pour fresh oil into the Kamaz-6520 wheel drive housings. To do this, install the wheels so that the manufacturer's trademark inscription is in a horizontal position, and fill with oil to the level of the lower edge of the inspection hole. After this, screw the plugs into place and after a few minutes, fill the oil to the level in the main gear housing. Malfunctions of the drive axle KamAZ-6520 Increased noise of the main gear Excessive or insufficient amount of oil in the crankcases of the main and wheel gears - Check and bring the oil level in the crankcase to normal Oil leakage Contamination of the breather - Clean the breather Adjust the Kamaz-6520 cross-axle differential locking mechanism in the following order : — remove the main gear; — remove the cover of the locking mechanism; — remove the piston with the rod; — install the locking clutch in a position in which the distance from plane A of the clutch ring gear to the axis of the hole d = 338+0.215 mm in the KamAZ-6520 axle housing is 168 mm; — measure dimension B from the surface of the fork pin to the reference plane of the crankcase flange; — assemble the piston with the rod in size B+7 mm, lock it with a nut and install it in the axle housing. Tighten the bolts securing the cover and diaphragm evenly. The tightening force should ensure tightness without excessive compression of the sides of the diaphragm; — check the travel of the locking clutch when supplying air to the diaphragm, which should be 14 mm. Kamaz 65115 dump truck axles Design of Kamaz-65115 drive axles On vehicles with a 6x4 wheel arrangement Kamaz-65115 and their modifications, middle and rear axles with a central two-stage main gear are installed. The design of the rear and middle axles is similar, the difference lies in the installation on the middle axle of a center locking differential and individual original parts mating with it. Depending on the purpose or operating conditions of various modifications of Kamaz vehicles, their drive axles differ from each other: - the final drive ratio (7.22; 6.53; 5.94; 5.43) - the presence of a cross-axle differential lock; — flanges for fastening cardan shafts; — axle housing depending on the vehicle’s load capacity; - axle shafts; — brake mechanisms (automatic or non-automatic adjustment levers, the presence of ABS, brake lining material, size and type of brake chambers, etc.). Figure 1 shows a cross-section of the rear and middle drive axles of the Kamaz-65115, 53229 vehicle.

Fig.1. Drive axle KamAZ-65115, 53229 1 - hub with brake drum; 2 - axle; 3 - cuff; 4 - ring; 5 — caliper mounting flange; 6- spring support; 7 — axle housing; 8 — axle shaft; 9 — safety valve; 10 — main gear; 11 — nut securing the main gear; 12 — axle housing support flange; 13 — magnetic plug; 14 - axle housing cover; 15 — reaction rod lever; 16 — brake mechanisms; 17 — ring gear of the ABS rotor; 18, 20 — tapered roller bearing; 19 — wheel rim mounting bolt; 21 — axle shaft gasket; 22 - axle mounting nut The drive axle KamAZ-65115, 53229 consists of an axle housing 7 with suspension elements, a main gear 10, axle shafts 8, a hub with a brake drum 1 and brake mechanisms 16. The axle housing KamAZ-65115, 53229 consists of two welded between consisting of stamped beams, with a welded crankcase flange 12 on top, and a crankcase cover 14 on the bottom. To the ends of the beam, its cross-section goes from rectangular to annular, where axles 2 are welded by friction welding, intended for installing wheel hubs on bearings 18 and 20. From the outer cylindrical surface At each end of the beam, flanges 5 are welded, intended for installing wheel brake calipers with pads. The cross-section of the beams in the areas under the springs is rectangular. In the middle part, the beam is widened and forms a so-called “banjo” to allow installation of the main gear. The axle housing of KamAZ-53215, 54115 vehicles has a wall thickness of 11 mm, the axle housing of KamAZ-53229, 65115 vehicles has a wall thickness of 14 mm. The rear axle housing is not interchangeable with the middle axle housing along the reaction rod arms (item 15, Fig. 1). Before installing bearings 18 and 20, ring 4 of cuff 3 is pressed onto the axle 2. The inner ring of the bearing 20 is mounted on the axle with a sliding fit, and the outer ring is pressed into the annular recess of the hub 1. To prevent lubricant from leaking out of the hub cavity, a cuff is pressed into it from the inside 3. The hub assembly with the cuff, bearings 18 and the outer ring of the bearing 20 is installed on the axle. After this (Fig. 2), the inner ring with the bearing rollers is mounted on it, the lock washer 5 and the bend washer 3 are put on, and a special bearing nut 1 is screwed on, which regulates the axial clearance of the hub bearings. It is fixed in a given position by a lock washer 5, the tendril of which fits into the groove of the trunnion, and into one of the holes there is a spherical extrusion on the bend washer 3. From unscrewing, the nut 1 is locked by bending it onto the edge of the bend washer. To prevent lubricant from flowing from the main gear cavity to the hub cavity, a lip seal is installed, containing a lip seal 2, a spacer ring 4 and a plug 6 in the axle groove. Fig. 2. Seal of the Kamaz 1 hub bearing mounting unit - bearing nut; 2 - cuff; 3 — folding washer; 4 — spacer ring; 5 — lock washer; 6 — plug The axle shaft 8 is attached to the hub 1 of the wheel (Fig. 1) on studs. Conical expansion bushings are put on the studs. The parts for installing the rear suspension are welded to the KamAZ axle housing: on top of both ends of the rear spring support 6, on the bottom - the levers 15 of the rear suspension reaction rods. A safety valve 9 is provided for ventilation of the crankcase cavity, and a magnetic plug 13 is provided for draining the lubricant. The axle shafts of the unloaded type are made for Kamaz 53229, Kamaz 65115 vehicles from 40ХН2МА steel, and for KamAZ 53215 vehicles from 50GF steel and have a different appearance. The right and left axle shafts differ in length. The surface of the axle shafts is hardened along the entire length with heating. h. The flange of the axle shaft has two threaded holes M12x1.25, designed to facilitate its dismantling. Gearbox (main gear) of KamAZ-65115 bridges The main gear of the KamAZ 65115 gearbox (Fig. 3) is two-stage, consists of a gearbox housing, a pair of spiral bevel gears and a pair of helical spur gears. The design of the main drive (gearbox) of KamAZ 65115 makes it possible to obtain 4 gear ratios by changing the number of teeth of only a spur gear pair without changing other parts. The Kamaz 65115 gearbox housing for the middle and rear axles is cast from high-strength cast iron, is structurally identical and is mounted on top of the axle beams using pins, four of which are equipped with conical expansion bushings. The drive bevel gear 10 of the rear axle KamAZ-65115 differs from the bevel gear of the middle axle 29 in the length of the hub. Gears are made of high quality alloy steel. Each gear has a hole. At the same time, for the middle axle gear it is cylindrical, designed to ensure the passage of shaft 31 of the rear axle drive; for the KamAZ 65115 rear axle gear it is splined, designed to connect to the drive shaft 11. The gears are installed in the gearbox housing on two tapered bearings 7 and 9. Bearings The rear and middle axles are interchangeable, but the gear set for each axle is original.

Fig.3. Main gearbox of the rear and intermediate axles KamAZ-65115 (longitudinal section) 1, 44 - drive flange; 2 — washer; 3, 33, 45 — bearing cover with cuff; 4 - gasket; 5, 27 — bearing cup; 6 — adjusting gaskets; 7, 9 — tapered roller bearing; 8 — adjusting sleeve; 10, 29 — bevel gear; 11 — drive shaft; 12 — gear housing; 13 — radial roller bearing; 14 — rear shaft cover; 15, 43 — flange mounting nut; 16 — cover gasket; 17 — center differential housing; 18 — front cup; 19 — rear axle drive gear; 20 — satellite center differential; 21 — crosspiece of the center differential; 22 — control sensor for turning on the center differential; 23 — rod of the locking mechanism; 24 — locking fork; 25, 30 — filler plug; 26 — locking clutch; 28 — drive mechanism for locking the center differential; 31 — rear axle drive shaft; 32, 46 — ball bearing; 34 — bearing fastening nut; 35 — lock washer; 36 — lock washer; 37 — locknut for fastening bearings; 38 — half-clutch locking center differential; 39 — middle axle drive gear; 40 — rear center differential cup; 41 — support washer; 42 — self-locking bolt

Fig.4. Main gearbox of the rear and intermediate axles of KamAZ-65115 (cross section) 1 — gearbox housing; 2 — radial roller bearing; 3 — driven bevel gear; 4 - key; 5 — cylindrical drive gear; 6, 8, 19 — tapered roller bearing; 7 — adjusting sleeve; 9 — adjusting gaskets; 10 — cup of bearings; 11 - gasket; 12 — bearing cover; 13 — support washer; 14 — bearing fastening nut; 15 — crosspiece of cross-axle differential; 16 — satellite support washer; 17 — satellite; 18 — adjusting nut; 20 — support washer for the semi-axial gear; 21 — stopper; 22 — differential bearing cover; 23, 26 — differential cup; 24 — semi-axial gear; 25 — cylindrical driven gear; 27 - half-clutch locking inter-wheel differential Differential KamAZ-65115 The inter-wheel differential KamAZ 65115 (Fig. 4) consists of the right 23 and left 26 cups, a cross 15, four satellites 17 and two semi-axial gears 24. The Kamaz 65115 differential cups are processed assembled and branded in order kit number. The material of the cups is high-strength cast iron. The cups have holes bored out for installing crosspieces and semi-axial gears. Kamaz 65115 differential satellites on bronze bushings are installed on a crosspiece, which, in turn, is installed in the sockets of the differential cups. To prevent wear, steel support washers 16 are installed between the surfaces of the differential cups and the ends of the satellites. The side gears 24 are installed in holes bored into the differential cups. Between the end of the rear part of the gear and the Kamaz 65115 differential cup, to prevent wear of the latter, a steel support washer 20 is installed, which has ball grooves on one side. The washers must be installed with the ball grooves facing the gears. Adjustment of the preload of bearings 19 is carried out using adjusting nuts 18, which have grooves, one of which, after adjusting the differential bearings, includes a stopper antenna 21. The bearing caps of the KamAZ 65115 differential are attached to the gearbox housing with two bolts, under the heads of which support washers are installed. To prevent the bolts from unscrewing, they are secured with wire or locking lock washers, which are secured from falling out with cotter pins. To ensure correct alignment of the bearing cover with the Kamaz 65115 gearbox housing, two pins are pressed into it, which are installed during joint machining. The Kamaz 65115 center differential (Fig. 3) is designed to distribute torque between the rear and middle axles, as well as to prevent power circulation between the drive axles when driving on paved roads (in the presence of kinematic mismatch between the axles or when there is a significant difference between the radii rolling of their drive wheels). Kamaz-53229, Kamaz-65115 and their modifications are equipped with a symmetrical, lockable, geared bevel center differential. The Kamaz 65115 differential consists of a differential housing 17 left 18 and right 40 cups, four satellites 20, a cross 21, a middle axle drive gear 39, a rear axle drive gear 19, a ball bearing 46, a bearing cap 45 and a flange 44. In the upper part of the Kamaz crankcase 65115 there are holes for installing the differential lock mechanism 28. Differential cups 18 and 40 are connected to each other by self-locking bolts 42. In each cup, surfaces are machined for satellite support washers and bevel gears, and also holes are bored for installing gear 19 of the KamAZ 65115 rear axle drive in the front cup 18, and gears 39 in the rear cup 40. middle axle drive. The assembled cups have holes bored out for installing the differential crosspiece 21. To ensure the supply of lubricant to the rubbing surfaces, three inclined holes are drilled in each cup. The rear cup ends with a cylindrical neck with a gear ring cut on it, designed to ensure blocking of the KamAZ-65115 center differential. On the neck of the front cup there are rectangular slots cut, intended for installation of the drive flange 44. The flange is fixed on the neck with a nut 43. The satellites 20 of the Kamaz-65115 differential are installed on the spikes of the cross on bronze bushings. To prevent wear of the differential cups, steel support washers with special ball recesses are installed between the back of the gears and the cups to create the necessary supply of lubricant. The Kamaz-65115 middle axle drive gear is installed in the rear differential cup. To ensure running-in and reduce wear, the gear is phosphated. To prevent cup wear, a steel support washer is installed between the rear end of the teeth and the cup. The rear axle drive gear 19 is installed in the front differential cup KamAZ 65115. The outer cylindrical surface of the gear journal is machined and is designed for installation in the front differential cup. The gear has a splined hole designed for connection with the splined end of the through shaft 31 of the rear axle drive. The KamAZ 65115 differential assembly is mounted on two supports, one of which is a ball bearing 46 installed in the differential housing socket, and the other is the cylindrical surface of the drive bevel gear 29 of the middle axle, installed in the gearbox housing on two bevel bearings. The axial forces arising during the operation of the transmission are absorbed by ball bearing 46. To prevent lubricant leakage from the KamAZ 65115 center differential housing, a cuff is pressed into the bearing cover 45, and to prevent dust and dirt from entering the flange, a mud deflector is welded to the flange. The Kamaz-65115 center differential locking mechanism 28 is installed in the upper part of the center differential housing. The KamAZ 65115 center differential locking mechanism is designed for forced differential locking when driving on slippery and wet dirt roads and is attached to the center differential housing 17 with two bolts. On the rod 23 of the locking mechanism there is a clutch fork 24, which with its claws fits into the annular recess of the locking clutch 26. The Kamaz-65115 differential locking clutch has an internal spline hole designed to lock the rear differential cup and clutch 38 of the middle axle drive gear. The Kamaz-65115 middle axle drive gear clutch has a splined hole inside to ensure installation on the gear, and on the outside there are two rings cut with which it engages with the splined hole of the locking clutch. To ensure remote activation of the Kamaz-65115 locking mechanism, a tap for the locking mechanism is installed in the driver’s cabin on the right side of the steering wheel on the instrument panel, and a signal lamp indicating the activation of the center lock is installed in the control lamp block.

_______________________________________________________________________________

Clutch KamAZ-5320 and its components
Repair of PGU and Kamaz clutch master cylinder
Gearbox gearbox KamAZ 141
Gearbox gearbox KamAZ ZF 16
Gearbox 152 Kamaz with divider
Gearbox gearbox 154 Kamaz
Gearbox Kamaz-4308
Clutch of a Kamaz-4308 car
Clutch and gearbox KamAZ-65115
Disassembly and assembly of Kamaz-4310, 55111, 43118 gearboxes

_______________________________________________________________________________

Cylinder block, head and valves Kamaz-740
Fuel system of Kamaz-740 diesel engine
Adjustments and repairs of fuel injection pump Kamaz-740

Drive axles of the Kamaz-4310 vehicle
Repair of Kamaz drive axle gearbox
Rear axle KamAZ-4308
Axles and suspensions of Kamaz-65115 dump trucks
Installation of Kamaz cardan shafts and axles
Repair of Kamaz vehicle transfer case

Kamaz power steering - adjustments and repairs
Repair of Kamaz steering gear parts
Steering parts Kamaz-4308
Parts of the brake system Kamaz-4308
Brake system and brake drive Kamaz
Repair of brake valves and Kamaz compressor

Suspension Kamaz-4310, 55111, 43118 and their parts
Frame and suspension of the Kamaz-4308 car
Cabin details and platform KamAZ-65115
Cabin components Kamaz-4308
Platform mechanism of Kamaz vehicles

Klintsy KS 65719-5K truck crane based on KamAZ-6522 chassis
Truck crane KC-35719-7-02 based on Kamaz-43118 chassis
Truck crane Galichanin KC-55713-1K based on KamAZ-65115 6x4
Ivanovets KS-45717K-1/1R truck crane based on KamAZ-65115 chassis
Ivanovets KS-3577-3/4 truck crane on KamAZ-43253 4x2 chassis

Adjusting the rear axle gearbox KAMAZ

The KamAZ 5320 gearbox is a mechanism that converts and transmits torque from the crankshaft to the wheels. This device experiences serious loads and requires regular inspections, adjustments, and repairs.

Adjusting the KamAZ 5320 axle gearbox

After repairing or replacing spare parts, the unit must be adjusted. The following parameters are adjusted in the crankcase: pre-tensioning of bearings on a gear pair of conical wheels, center differential, side clearance and contact mark on gear teeth.

The preload of the bearings on the wheelsets is adjusted in the following order:

Center differential of the KamAZ-5320 car

sharpening or replacing adjusting washers to reduce the thickness of the package by an amount of axial displacement from 0.04 to 0.06 mm;
tightening the fastening nut of the bevel gear flange (force from 240 to 360 N);
measurement of the rotation force of the bearing cup under conditions of continuous rotation (5 revolutions) in one direction.

The turning force should be in the range from 11.4 N to 22.8 N. If the obtained value is not within the indicated limits, then the adjustment should be repeated.

uniformly tighten the adjusting nuts on both sides until a gap is obtained between the bearing tires;
measuring the gap (the value should be 0.1–0.2 mm);
tightening the fastening bolts of the covers with a force of 250–320 N.

Differential of the rear drive axle KamAZ-5320

How to determine malfunctions of the KamAZ 5320 axle gearbox

This unit in KamAZ vehicles rarely breaks down, but constant and serious loads still make themselves felt. A clear signal of a component malfunction is noise when the car is moving, although it can serve as evidence of breakdowns of other components. Diagnosis of a bridge gearbox malfunction based on noise can be performed in three stages, and each stage can serve as a separate way to identify a breakdown.

Axles of KAMAZ vehicles

Acceleration, deceleration with the engine running and gear engaged:

while driving the car at a speed of 25 km/h, listen to the engine;
during the process of gradually accelerating the car to 85 km/h, determine the beginning of the noise and the moment it subsides;
Gradually reduce the speed (without braking) to 25 km/h and determine the moment when the noise appears and subsides;

If extraneous sounds appear and subside at the same speed during acceleration and braking, then the KamAZ middle axle gearbox is to blame. It is necessary to carry out the next stage of diagnosis.

Pressure reducing valve KamAZ-5320

Acceleration, neutral and engine off:

accelerate the car to 80 km/h;
Move the gear lever to neutral speed;
turn off the engine;
listen to the engine.

There is no noise when drifting, but when there is load, the axle gearbox is faulty. You can be completely sure by doing the third step.

"Progazovka" on site:

turn on the engine and rev it up well;
listen to the engine.

If there are no noises detected at the first stage, the unit is definitely faulty and requires repair or replacement.

What to look for when inspecting the KamAZ 5320 axle gearbox

There are three types of failures of the KamAZ 5320 axle gearbox:

increase in main gear temperature;
leakage of lubricant;
noise amplification.

The main reasons for the increase in temperature of the axle gearbox:

There is little or, conversely, a lot of oil in the crankcase. The problem can be corrected either by adding oil or draining the excess.
Increased bearing tension. It needs to be adjusted.
The gears in the gears are set incorrectly. Also eliminated by adjustment.

The KamAZ 5320 rear axle gearbox, which is very noisy, has one of the following malfunctions:

Rear axle KAMAZ 5320

The tapered bearings are worn out. To fix the problem, you need to adjust or replace the bearings.
Meshing in gears is broken . This problem occurs when the side clearance is incorrect or the contact patch is misaligned. Adjust the unit to get rid of the noise.
Gear teeth are severely worn or damaged. Replace the gear pair and immediately adjust the side clearance.
Bearings are loose. Tighten the roller bearing nuts and adjust their rotation force.

The main reasons for oil leaks from the crankcase:

Wear the cuff. The solution to the problem is to replace the old spare part.
Breather contamination. Clean and rinse the part.

Dismantling the intermediate axle gearbox of KamAZ vehicles

To disassemble this unit you need:

Unscrew the bolts of the differential cup and remove it;
Unscrew the self-locking bolts of the drive wheel bearing housing;
remove the cotter pin and unscrew the nut, remove the washer and flange;
Unscrew the cover bolts and remove it;
remove the rear shaft.

Disassembling the drive bevel gear

To disassemble the drive bevel gear of the middle axle gearbox of a KamAZ truck, you must:

Unlock and unscrew the nut, remove the lock washer;
unscrew the bearing nut with the pin;
remove the glass, adjustment washers and spacer sleeve;
Remove the bevel bearing inner race from the drive bevel gear.

The KamAZ rear axle gearbox is disassembled in the same way.

More about replacing the KamAZ axle gearbox: the unit is selected according to such a key parameter as the number of engagements of the teeth of the driven gear with the teeth of the drive wheel, i.e., the gear ratio. The greater its value, the higher the traction torque of the mechanism and its price. Therefore, it is advisable to select these units according to operating conditions, namely:

Rear axle gearbox repair

if the car is operated on flat roads without a trailer, then the gear ratio should be from 4.98 to 5.43 gears;
when KamAZ is operated on flat roads with a trailer, the gear ratio should be from 4.98 to 5.43 gears;
operation of a road train on rough roads – from 6.53 to 7.22 gears;
road trains or KamAZ trucks without trailers on mountain roads - 7.22 gears.

Gearbox KAMAZ 65115 rear axle

In operating condition, heavy loads are placed on the KAMAZ 65115 rear axle gearbox, which leads to malfunctions. A gearbox refers to mechanisms whose main task is to change the rotation speed when transmitting rotational motion from one shaft to another.

The rear axle of the dump truck can be equipped with gears with or without interwheel locking.

Based on the number of teeth, units with 48, 49 teeth are most likely used, and for cars of 2008 65116, 65117, as a rule, 46 teeth are often used.

The price for the KAMAZ 65115 gearbox is current and includes VAT 18%.

Gear articles by number of teeth:

53205-2402011-10 — 49 teeth 65115-2402011-60 — 46 teeth

Typical unit problems

Cars of this brand began to be produced 40 years ago. Over these many years, three main failures were identified in the KAMAZ 65115 rear axle gearbox assembly: 1. The KAMAZ 65115 rear axle gearbox is operated with high oil consumption; 2. The KAMAZ 65115 gearbox has increased noise; 3. The KAMAZ 65115 gearbox is characterized by increased heating of the transmission gear mechanism.

The reasons why the KAMAZ 65115 rear axle gearbox gets very hot: - a problem with the amount of lubricant, to solve this problem you need to correct its volume; — incorrect adjustment of the gear engagement; it needs to be adjusted to correct it; - incorrect bearing tension, repaired by adjustment

The KAMAZ 65115 rear axle gearbox can create loud noise caused by the following reasons: - loosening of the bearing holders, which can be corrected by tightening the fastening nuts; — damping of tapered bearings or their shift along the axis, eliminated by adjustment or replacement of a worn part; - wear or breakage of teeth on gear wheels, repaired by installing a new part; - a defect in the meshing of gears, which can be eliminated by adjusting the side clearance.

The KAMAZ 65115 rear axle gearbox can consume a lot of oil for two reasons. The first of them is due to wear of the cuff. And the second occurs in case of contamination of the breather. They are corrected either by replacing the cuff or by cleaning in the second case. Oil change

The main gear has a special control plug on the housing. Filling occurs until drops appear from the control hole.

We have a KAMAZ 65115 gearbox of any model, to buy please contact the sales department by phone